Method and arrangement for building metallic objects by solid freeform fabrication using plasma transferred arc (PTA) torches

ABSTRACT

This invention relates to a method and arrangement for manufacturing objects by solid freeform fabrication, especially titanium and titanium alloy objects, wherein the deposition rate is increased by supplying the metallic feed material in the form of a wire and employing two gas transferred arcs, one plasma transferred arc for heating the deposition area on the base material and one plasma transferred arc for heating and melting the feed wire.

This application is a continuation application of U.S. patentapplication Ser. No. 14/008,307, filed Nov. 8, 2013, now U.S. Pat. No.9,481,931, which was the National Stage of International PatentApplication No.: PCT/NO2012/000033, Mar. 30, 2012, which claims priorityto United Kingdom Patent Application No.: 1105433.5, filed Mar. 31,2011, all of which are incorporated herein by reference.

BACKGROUND

This invention relates to a method and reactor for manufacturing objectsby solid freeform fabrication, especially titanium and titanium alloyobjects. Structured metal parts made of titanium or titanium alloys areconventionally made by casting, forging or machining from a billet.These techniques have a disadvantage of high material use of theexpensive titanium metal and large lead times in the fabrication.

Fully dense physical objects may be made by a manufacturing technologyknown as rapid prototyping, rapid manufacturing, layered manufacturingor additive fabrication. This technique employs computer aided designsoftware (CAD) to first construct a virtual model of the object which isto be made, and then transform the virtual model into thin parallelslices or layers, usually horizontally oriented. The physical object maythen be made by laying down successive layers of raw material in theform of liquid paste, powder or sheet material resembling the shape ofthe virtual layers until the entire object is formed. The layers arefused together to form a solid dense object. In case of depositing solidmaterials which are fused or welded together, the technique is alsotermed as solid freeform fabrication.

Solid freeform fabrication is a flexible technique allowing creation ofobjects of almost any shape at relatively fast production rates,typically varying from some hours to several days for each object. Thetechnique is thus suited for formation of prototypes and smallproduction series, but less suited for large volume production.

The technique of layered manufacturing may be expanded to includedeposition of pieces of the construction material, that is, eachstructural layer of the virtual model of the object is divided into aset of pieces which when laid side by side form the layer. This allowsforming metallic objects by welding a wire onto a substrate insuccessive stripes forming each layer according to the virtual layeredmodel of the object, and repeating the process for each layer until theentire physical object is formed. The accuracy of the welding techniqueis usually too coarse to allow directly forming the object withacceptable dimensions. The formed object will thus usually be considereda green object or pre-form which needs to be machined to acceptabledimensional accuracy.

Taminger and Hafley [1] disclose a method and device for manufacturingstructural metal parts directly from computer aided design data combinedwith electron beam freeform fabrication (EBF). The structural part isbuilt by welding on successive layers of a metallic welding wire whichis welded by the heat energy provided by the electron beam. The processis schematically shown in FIG. 1, which is a facsimile of FIG. 1 of [1].The EBF process involves feeding a metal wire into a molten pool madeand sustained by a focused electron beam in a high vacuum environment.The positioning of the electron beam and welding wire is obtained byhaving the electron beam gun and the positioning system (the supportsubstrate) movably hinged along one or more axis (X, Y, Z, and rotation)and regulate the position of the electron beam gun and the supportsubstrate by a four axis motion control system. The process is claimedto be nearly 100% efficient in material use and 95% effective in powerconsumption. The method may be employed both for bulk metal depositionand finer detailed depositions, and the method is claimed to obtainsignificant effect on lead time reduction and lower material andmachining costs as compared to the conventional approach of machiningthe metal parts. The electron beam technology has a disadvantage ofbeing dependent upon a high vacuum of 10⁻¹ Pa or less in the depositionchamber.

It is known to use a plasma arc to provide the heat for welding metallicmaterials. This method may be employed at atmospheric or higherpressures, and thus allow simpler and less costly process equipment. Onesuch method is known as gas tungsten arc welding (GTAW, also denoted asTIG) where a plasma transferred arc is formed between a non-consumabletungsten electrode and the welding area. The plasma arc is usuallyprotected by a gas being fed through the plasma torch forming aprotective cover around the arc. TIG welding may include feeding a metalwire or metal powder into the melting pool or the plasma arc as a fillermaterial.

From U.S. Patent Application Publication No.: 2010/0193480 it is knownto employ a TIG-welding torch to build objects by solid free-formfabrication (SFFF), where successive layers of metallic feedstockmaterial with low ductility are applied onto a substrate. A plasmastream is created by energizing a flowing gas using an arc electrode,the arc electrode having a variable magnitude current supplied thereto.The plasma stream is directed to a predetermined targeted region topreheat the predetermined targeted region prior to deposition. Thecurrent is adjusted and the feedstock material is introduced into theplasma stream to deposit molten feedstock in the predetermined targetedregion. The current is adjusted and the molten feedstock is slowlycooled at an elevated temperature, typically above the brittle toductile transition temperature of the feedstock material, in a coolingphase to minimize the occurrence of material stresses.

Another example is U.S. Patent Application Publication No.: 2006/0185473which discloses use of TIG torch in place of the expensive lasertraditionally used in a solid freeform fabrication (SFFF) process withrelatively low cost titanium feed material by combining the titaniumfeed and alloying components in a way that considerably reduces the costof the raw materials. More particularly, in one aspect the presentinvention employs pure titanium wire (CP Ti) which is lower in cost thanalloyed wire, and combines the CP Ti wire with powdered alloyingcomponents in-situ in the SFFF process by combining the CP Ti wire andthe powder alloying components in the melt of the welding torch or otherhigh power energy beam. In another embodiment, the invention employstitanium sponge material mixed with alloying elements and formed into awire where it may be used in an SFFF process in combination with aplasma welding torch or other high power energy beam to produce near netshaped titanium components.

Titanium metal or titanium alloys heated above 400° C. may be subject tooxidation upon contact with oxygen. It is thus necessary to protect theweld and heated object which is being formed by layered manufactureagainst oxygen in the ambient atmosphere.

One solution to this problem is known from International PatentApplication Publication No.: WO 2011/0198287 which discloses a methodfor increasing the deposition rate by performing the manufacturing ofobjects by solid freeform fabrication, especially titanium and titaniumalloy objects, in a reactor chamber which is closed to the ambientatmosphere. By making the deposition chamber sufficiently void ofoxygen, the need for employing protective measures to avoid oxidizingthe newly welded area by ambient atmospheric oxygen is no longerpresent, such that the welding process may proceed at a larger velocitysince the welded zone may be allowed to have a higher temperaturewithout risking excessive oxidation of the weld. For example, inproduction of objects of titanium or titanium alloy, there is no longerneed for cooling the welded zone to below 400° C. to avoid oxidation.

Another solution for increasing the deposition rate is known from U.S.Pat. No. 6,268,584 which discloses a deposition head assembly consistingof the following features: an array of output powder nozzles forcreating a converging flow of powder to the deposition region, a centralorifice which allows the multiple beams to be focused onto thedeposition substrate, and coaxial gas flow for each of the powdernozzles to concentrate the stream of powders from these nozzles in orderto provide a longer working distance between the nozzle and thedeposition head assembly. The longer working distance is critical toinsure that molten metal particulates are not attached to the depositionapparatus during processing. In particular, the invention includes amanifold system designed into the deposition head assembly that can usemore than one laser beam simultaneously for the deposition process. Thedeposition head assembly also incorporates a means for activelyconcentrating the powder stream from each orifice to increase materialutilization efficiency.

International Patent Application Publication No.: WO 2006/0133034discloses use of combined gas metal arc and laser welding to solve theproblems associated with the reactive nature of Ti and its moltencharacteristics which make it very difficult to form DMD products. Gasmetal arc techniques have several disadvantages that severely limittheir application to depositing Ti. These drawbacks includeinstabilities in metal transfer, excessive spatter, and poor control ofthe deposited layer shape, and high heat input that causes distortion ofthin sections during deposition. Also, an increase in productivity isnot possible because of wandering of the cathode spot that occurs duringdeposition. The solution to these problems according to InternationalPatent Application Publication No.: WO 2006/133034 is to a direct metaldeposition process comprising the steps of providing a substrate anddepositing a metal from a metal feedstock onto the substrate. Anelectric arc is generated between the metal feedstock and the substrateand the arc is exposed to laser radiation to form a molten metal pool onthe substrate. The molten metal pool is cooled to form a first solidmetal layer on the substrate.

SUMMARY OF THE INVENTION

The main objective of the invention is to provide a device for buildingmetallic by solid freeform fabrication.

Another objective of the invention is to provide a method for rapidlayered manufacture of objects in titanium or titanium alloys.

The invention is based on the realization that the deposition rate maybe increased by supplying the metallic feed material in the form of awire and employing two gas transferred arcs, one plasma transferred arcfor heating the deposition area on the base material and one plasmatransferred arc for heating and melting the feed wire.

Thus in a first aspect, the present invention relates to a method formanufacturing a three-dimensional object of a metallic material by solidfreeform fabrication, where the object is made by fusing togethersuccessive deposits of the metallic material onto a holding substrate,characterized in that the method comprises:

employing a holding substrate made of a similar metallic material as theobject is to be made of, and

each successive deposit is obtained by;

i) employing a first plasma transferred arc (PTA) to preheat and form amolten pool in the base material at the position at which the metallicmaterial is to be deposited,

ii) feeding the metallic material to be deposited in the form of a wireto a position above the molten pool,

iii) employing a second plasma transferred arc (PTA) to heat and meltthe wire such that molten metallic material is dripping into the moltenpool, and

iv) moving the holding substrate relative to the position of the firstand second PTA in a predetermined pattern such that the successivedeposits of molten metallic material solidifies and forms thethree-dimensional object.

In a second aspect the invention relates to an arrangement formanufacturing a three-dimensional object of a metallic material by solidfreeform fabrication, where the arrangement comprises:

a welding torch with an integrated wire feeder feeding a wire of themetallic material,

a system for positioning and moving the holding substrate relative tothe welding torch, and

a control system able to read a computer assisted design (CAD) model ofthe object which is to be formed and employ the CAD-model to regulatethe position and movement of the system for positioning and moving theholding substrate and to operate the welding torch with integrated wirefeeder such that a physical object is built by fusing successivedeposits of the metallic material onto the holding substrate,characterized in that

the holding substrate is made of a similar metallic material as theobject that is to be made,

the welding torch comprises:

i) a first plasma transferred arc (PTA) torch electrically connected tothe base material and

ii) a second plasma transferred arc (PTA) torch electrically connectedto the feed wire of metallic material,

the control system is able to separately operate and regulate the firstPTA-torch to form and maintain a molten pool in the base material at theposition at which the metallic material is to be deposited, and

the control system is able to separately operate and regulate the wirefeeder and the second PTA-torch to melt the metallic material feed in aposition such that molten metallic material drips into the molten pool.

The term “similar metallic material” as used herein means that themetallic material is of the same metal or metal alloy as the referencemetallic material.

The term “base material” as used herein means the target material forthe heat from the first PTA-torch and which the molten pool is to beformed. This will be the holding substrate when depositing the firstlayer of metallic material. When one or more layers of metallic materialhave been deposited onto the holding substrate, the base material willbe the upper layer of deposited metallic material that is to havedeposited a new layer of metallic material.

The term “plasma transferred arc torch” or “PTA-torch” as usedinterchangeably herein means any device able to heat and excite a streamof inert gas to plasma by an electric arc discharge and then transferthe flow of plasma gas including the electric arc out through an orifice(nozzle) to form a constricted plume which extends out of the orificeand transfers the intense heat of the arc to a target region. Theelectrode and target region is electrically connected to a directcurrent power source such that the electrode of the PTA-torch becomesthe cathode and the target region becomes the anode. This will ensurethat the plasma plume including electric arc is delivering a highlyconcentrated heat flow to a small surface area of the target region withexcellent control of the areal extension and magnitude of the heat fluxbeing supplied from the PTA-torch. A plasma transferred arc has theadvantage of providing stable and consistent arcs with little wanderingand good tolerance for length deviations between the cathode and anode.Thus, the PTA-torch is suitable both for forming a molten pool in thebase material and to heat and melt the metallic wire feed. The PTA-torchmay advantageously have an electrode made of tungsten and a nozzle madeof copper. However, the invention is not tied to any specific choice ortype of PTA-torch. Any known or conceivable device able to function asPTA-torch may be applied.

The use of a separately controlled first PTA-torch to preheat the basematerial and form the molten pool and a separately second PTA-torch tomelt the feed wire of metallic material provides the advantage that itbecomes possible to increase the heat supply to the feed of the metallicwire independently of the heat supply to the substrate such that itbecomes possible to increase the heat flux into the feed material withno risk of creating a “spray arc” which generates spatter. Thus, it ispossible to increase the deposition rate of the molten metallic feedmaterial without simultaneously over-heating the substrate and withoutrisk of spatter or form an excessive molten pool and thus, loose controlof the consolidation of the deposited material. This feature is obtainedby connecting a direct current power source such that the electrode ofthe first PTA-torch becomes the negative polarity and the base materialbecomes the positive polarity to define an electric circuit whereelectric charge is transferred by an arc discharge between the electrodeof the first PTA-torch and the base material, and by connecting theelectrode of the second PTA-torch to the negative pole of a directcurrent power source and the feed wire of metallic material to thepositive pole to form an electric circuit where electric charge istransferred by an arc discharge between the electrode of the secondPTA-torch and the feed wire of metallic material.

The first and second PTA-torches may advantageously have separate powersources and means for regulating the power supply to the respectivetorches. The means for regulating the power may advantageously includemeans for monitoring the temperature of the deposition area of the basematerial and means for regulating the width and positioning of the arcsuch as i.e. magnetic arc deflection means. Also, the first PTA-torchemployed to form the molten pool in the base material may advantageouslyform a wide arc, such as i.e. formed by a gas tungsten arc welding torch(GTAW-torch, also denoted as TIG-torch in the literature) to form amolten pool in a wider area of the surface of the base material.

The term “computer assisted design model” or “CAD-model” as usedinterchangeably herein means any known or conceivable virtualthree-dimensional representation of the object that is to be formedwhich may be employed in the control system of the arrangement accordingto the second aspect of the invention: to regulate the position andmovement of the holding substrate and to operate the welding torch withintegrated wire feeder such that a physical object is built by fusingsuccessive deposits of the metallic material onto the holding substratein a pattern which results in building a physical object according tothe virtual three-dimensional model of the object. This may for instancebe obtained by forming a virtual vectorized layered model of thethree-dimensional model by first dividing the virtual three-dimensionalmodel into a set of virtual parallel layers and then dividing each ofthe parallel layers into a set of virtual quasi one-dimensional pieces.Then, the physical object may be formed by engaging the control systemto deposit and fuse a series of quasi one-dimensional pieces of themetallic material feed onto the supporting substrate in a patternaccording to the first layer of the virtual vectorized layered model ofthe object. Then, repeating the sequence for the second layer of theobject by depositing and fusing a series of quasi one-dimensional piecesof the weldable material onto the previous deposited layer in a patternaccording to the second layer of the virtual vectorized layered model ofthe object. Repetition continues the deposition and fusing process layerby layer for each successive layer of the virtual vectorized layeredmodel of the object until the entire object is formed. However, theinvention is not tied to any specific CAD-model and/or computer softwarefor running the control system of the arrangement according to theinvention, and nor is the invention tied to any specific type of controlsystem. Any known or conceivable control system (CAD-model, computersoftware, computer hardware and actuators etc.) able to build metallicthree-dimensional objects by solid freeform fabrication may be employedas long as the control system is adjusted to separately operate onefirst PTA-torch to form the molten pool and a second PTA-torch to meltthe feed wire of metallic material into the molten pool.

The feed rate (the wire speed) and positioning of the feed wire ofmetallic material may advantageously be controlled and regulated inaccordance with the effect of the power supply to the second PTA-torchin order to ensure that the wire is being continuously heated and meltedwhen reaching the intended position above the molten pool in the basematerial. This may be obtained by using a conventional gas metal arcwelding torch (GMAW-torch, also denoted MIG-torch) as wire feederwithout forming an arc in the MIG-torch. This embodiment of the wirefeeder has the advantage of being able to electrically connect the wireto the DC power supply of the second PTA-torch and also to position thewire very accurately. The feed wire of metallic material may have anypractically implementable dimension, such as i.e. 1.0 mm, 1.6 mm, 2.4mm, etc.

The term “metallic material” as used herein means any known orconceivable metal or metal alloy which may be formed into a wire andemployed in a solid freeform fabrication process to form athree-dimensional object. Examples of suitable materials include, butare not limited to; titanium and titanium alloys such as i.e. Ti-6Al-4Valloys.

The supplied effect to the first and second PTA-torch will depend onwhich metallic material is being applied, the diameter of the feed wire,the heat tolerances of the base material, the deposition rate etc. Theinvention is therefore not tied to any specific window of power supply,but may apply any practically functioning potential difference andcurrent which results in a functioning operation of the first and secondPTA-torch. A skilled person will be able to find these parameters bytrial and error tests. Experiments performed by the applicant has shownthat by employing a wire with diameter of 1.6 mm made of grade 5titanium alloy, it may be built three-dimensional objects with similarmechanical properties as conventional objects of titanium at adeposition rate of 3.7 to 3.8 kg/hour when the first PTA-torch issupplied with around 150 A and the second PTA-torch with around 250 A.It is believed that deposition rates up to 10 kg/hour may be obtained byperforming the SFFF-deposition according to the first and second aspectof the invention in an effectively protected atmosphere, such as i.e. inthe reaction chamber disclosed in International Patent ApplicationPublication No.: WO 2011/0198287. This is confirmed by anotherexperiment performed by the applicant with wire diameter 2.4 mm, grade 5titanium, which gave a deposition rate of 9.7 kg/h when supplying thefirst PTA torch a current of around 250 A and the second PTA torch witha current of around 300 A.

As an alternative, the invention may also include means for creatingthermal pulses in the molten pool in order to break down tendencies togrowth of crystalline dendrites in the molten pool. This feature allowsforming metallic objects with enhanced mechanical properties due to animproved grain structure. The thermal pulsing may be obtained byemploying a third DC power generator which delivers a pulsatingDC-potential and connecting the negative pole of the DC power generatorto the electrode of the second PTA-torch and the positive pole to thebase material to form an electric circuit where electric charge istransferred by an pulsating arc discharge between the electrode of thesecond PTA-torch and the base material. The arc discharge between theelectrode of the second PTA-torch and base material will be turned onand off in accordance with the applied pulsating DC-potential and thusform a pulsating heat flux into the molten pool in the base material.The frequency of the pulsing may be in the range from 1 Hz up to severalkHz or more, i.e. 10 kHz.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a facsimile of FIG. 1 of Taminger and Hafley [1] showing aschematic view of the principle of solid freeform fabrication.

FIG. 2 is a facsimile of FIG. 1 of U.S. Patent Application PublicationNo.: 2006/0185473 showing a schematic view of the principle of plasmatransferred arc solid freeform fabrication.

FIG. 3 is a schematic drawing showing a cross-section view of thearrangement according to the second aspect of the present invention.

FIG. 4 is a schematic drawing showing a cross-section view of a secondembodiment of the invention including thermal pulsing.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

The invention will be explained in greater detail by way of exampleembodiments. These examples should not be interpreted as a limitation ofthe general scope of the inventive idea of using two PTA-torches, one toform the molten pool in the base material and one to melt the feedmaterial.

First Example Embodiment

The first example embodiment of the arrangement according to secondaspect of the invention is shown schematically in FIG. 3. The figureshows a holding substrate 1 made of a Ti-6Al-4V alloy shaped as arectangular cuboid, onto which a three-dimensional object made of thesame Ti-6Al-4V alloy is to be formed by solid freeform fabrication. Thefigure displays the initial part of the deposition process where thefirst welding stripe 2 of Ti-6Al-4V alloy is being deposited.

A wire 3 made of the Ti-6Al-4V alloy is continuously being supplied by awire feeder 4 which positions the wire 3 such that its distal end islocated above the molten pool 5 at the deposition area on the holdingsubstrate 1. The wire 3 is given a velocity indicated by the upper arrowon the Figure which corresponds to the heating and melting rate of thedistal end such that droplets 6 of molten wire are continuously beingsupplied to the molten pool 5.

A first plasma transferred arc 7 is formed by a PTA-torch 8 which iselectrically connected to a DC power source 9 such that the electrode 10of the PTA-torch becomes the cathode and the holding substrate 1 theanode. The plasma transferred arc 7 is continuous and directed to heatand melt the base material (which at this stage of the SFFF-process isthe holding substrate) at the deposition spot such that the molten pool5 is obtained. The effect of the DC power source 9 is regulated tomaintain a molten pool 5 with a constant size and extension by a controlsystem (not shown). The PTA-torch 8 is a gas tungsten arc welding (GTAW)torch equipped with a magnetic arc deflector (not shown) to control thesize and position of the arc 8.

A second plasma transferred arc 11 is formed by a PTA-torch 12 which iselectrically connected to a DC power source 13 such that the electrode14 of the PTA-torch 12 becomes the cathode and the feed wire 3 theanode. The plasma transferred arc 11 is continuous and directed to heatand melt the distal end of the wire 3. The effect of the DC power source13 is regulated to maintain a heating and melting rate in accordancewith the feeding velocity of the wire such that the formation of thedroplets 6 are timed to maintain a continuous drip of molten wire intothe molten pool 5. The effect supplied by the DC power source 13 and thefeeding velocity of the wire 3 exiting the wire feeder 4 are constantlyregulated and controlled by the control system 17 such that the moltenpool 5 is supplied with molten wire at a rate providing the intendeddeposition rate of the Ti-6Al-4V alloy. The control system 17 issimultaneously engaged to operate and regulate the engagement of anactuator (not shown) which constantly positions and moves the holdingsubstrate 1 such that the molten pool is located at the intendeddeposition spot as given by the CAD-model of the object that is to beformed. At this stage of the SFFF-process, the holding substrate 1 ismoved as indicated by the lower arrow.

Second Example Embodiment

The second example embodiment of the invention is the first exampleembodiment given above including additional means for forming thermalpulses in the molten pool 5.

The means for forming thermal pulses is a DC power source 15 which iselectrically connected to the second PTA-torch 12 such that theelectrode 14 becomes the cathode and the holding substrate 1 becomes theanode. In addition, there are means 16 for pulsing the power deliveredby DC power source 15 such that the arc 11 will in addition to heat andmelt the wire 3, enter into the molten pool 5 with the same frequency asthe pulsed power supply and thus deliver a pulsating heat flux to themolten pool. The means 16 may is regulated by the control system 17 andprovides a pulsing arc discharge into the molten pool with a frequencyof 1 kHz.

REFERENCE

1. Taminger, K. M. and Hafley, R. A., “Electron Beam FreeformFabrication for Cost Effective Near-Net Shape Manufacturing”,NATO/RTOAVT-139 Specialists' Meeting on Cost Effective Manufacture viaNet Shape Processing (Amsterdam, the Netherlands, 2006) (NATO). pp 9-25,http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/20080013538.sub.-20-08013396.pdf

The invention claimed is:
 1. A system for building metallic objects bysolid freeform fabrication, comprising: a first plasma transferred arctorch electrically connected to a base material and a second plasmatransferred arc torch electrically connected to a feed wire; and acontrol system to control the first and second torches, and the feedwire to form an object by fusing successive deposits of a metallicmaterial onto the base material.
 2. The system of claim 1, wherein theelectrical connection between the first plasma transferred arc torch andthe base material is achieved by a first power source, and theelectrical connection between the second plasma transferred arc torchand the feed wire is achieved by a second power source.
 3. The system ofclaim 2, wherein the first and second power sources are direct current.4. The system of claim 3, wherein the first and second direct currentpower sources include independent controls.
 5. The system of claim 1,wherein the first plasma transferred arc torch preheats the basematerial at a position at which the metallic material is to bedeposited.
 6. The system of claim 1, wherein the second plasmatransferred arc torch melts the feed wire.
 7. The system of claim 1,wherein at least one of the first and second plasma transferred arctorches includes arc deflection control.
 8. The system of claim 1,wherein the first plasma transferred arc torch is a gas tungsten arcwelding torch.
 9. The system of claim 1, wherein at least one of firstand second plasma transferred arc torches is a gas metal arc weldingtorch.
 10. The system of claim 1, further comprising an electricalconnection between the second plasma transferred arc torch and the basematerial.
 11. The system of claim 10, wherein the electrical connectionbetween the second plasma transferred arc torch and the base material isachieved by a power source independent from that of first plasmatransferred arc torch and second plasma transferred arc torch.
 12. Thesystem of claim 11, wherein the independent power source is directcurrent.
 13. The system of claim 12, wherein the direct currentindependent power source includes controls independent from that offirst plasma transferred arc torch and second plasma transferred arctorch.
 14. The system of claim 13, wherein the independent controlsinclude controls for a pulsating arc discharge between the second plasmatransferred arc torch and the base material.
 15. The system of claim 14,wherein the pulsating arc is pulsed with a frequency in the range from 1Hz to 10 kHz.
 16. The system of claim 1, wherein the first plasmatransferred arc torch is electrically connected to a first power sourcesuch that an electrode of the first plasma transferred arc torch becomesa cathode and the base material becomes an anode.
 17. The system ofclaim 1, wherein the second plasma transferred arc torch is electricallyconnected to a second power source such that an electrode of the secondplasma transferred arc torch becomes a cathode and the feed wire ofmetallic material becomes an anode.
 18. The system of claim 17, whereinthe second plasma transferred arc torch is further electricallyconnected to a third power source such that an electrode of the secondplasma transferred arc torch is also a cathode with the base material asa corresponding anode.
 19. A method for manufacturing athree-dimensional object of a metallic material by solid freeformfabrication, the method comprising: preheating a deposition area in abase material using a first plasma transferred arc; feeding a feed wireto a position above the preheated deposition area in the base material;and melting a distal end of the feed wire using a second plasmatransferred arc such that molten metallic material is deposited onto thepreheated deposition area in the base material.
 20. The method of claim19, further comprising independently controlling the first and secondplasma transferred arcs.
 21. The method of claim 19, wherein thepreheating of the deposition area in of the base material furthercomprises forming a molten pool in the base material.
 22. The method ofclaim 19, further comprising moving the base material relative to theposition of the first and second plasma transferred arcs in apredetermined pattern such that the successive deposits of moltenmetallic material drips on the preheated deposition area.
 23. The methodof claim 19, further comprising providing the first plasma transferredarc with a first plasma transferred arc torch electrically connected tothe base material by a first power source, and providing the secondplasma transferred arc with a second plasma transferred arc torchelectrically connected to the wire by a second power source.
 24. Themethod of claim 23, wherein the first and second power sources aredirect current.
 25. The method of claim 19, further comprisingcontrolling the deflection of at least one of the first and secondplasma transferred arcs.
 26. The method of claim 19, wherein the firstplasma transferred arc is generated by a gas tungsten arc welding torch.27. The method of claim 19, wherein at least one of first and secondplasma transferred arcs is generated by a gas metal arc welding torch.28. The method of claim 19, further comprising preheating the depositionarea in the base material using a third plasma transferred arc, whereinthe second plasma transferred arc and the third plasma transferred arcare both provided by a single plasma transferred arc torch that iselectrically connected to the wire via a power source, and to the basematerial via another power source.
 29. The method of claim 28, furthercomprising independently pulsating arc discharge between the plasmatransferred arc torch and the wire and the plasma transferred arc torchand the base material.
 30. The method of claim 29, wherein each powersource connected to the plasma transferred arc torch is a direct currentpower source pulsating with a frequency in the range from 1 Hz to 10kHz.
 31. The method of claim 28, wherein the preheating by the thirdplasma transferred arc forms a molten pool in the base material.
 32. Themethod of claim 19, wherein the metallic material is titanium or alloyedtitanium.
 33. The method of claim 19, further comprising: creating avirtual three dimensional model of the object; dividing the model into aset of virtual parallel layers and further into a set of virtual quasione-dimensional pieces for each parallel layer to form a virtualvectorized layered model of an object; loading the virtual vectorizedlayered model of the object into a control system able to regulate theposition and movement of the base material, and the activation of thefirst and second plasma transferred arcs; engaging the control system todeposit and fuse a series of quasi one-dimensional pieces of the moltenmetallic material onto the base material in a pattern according to thefirst layer of the virtual vectorized layered model of the object;forming the second layer of the object by depositing and fusing a seriesof quasi one-dimensional pieces of the molten metallic material onto theprevious deposited layer in a pattern according to the second layer ofthe virtual vectorized layered model of the object; and repeating thedeposition and fusing process layer by layer for each successive layerof the virtual vectorized layered model of the object until an entireobject is formed.